TPI November 2022

Analysing and optimising tube handling, maintenance and cleaning processes By Doris Schulz, Ecoclean GmbH

The cleaning experts not only focus on the actual cleaning process and equipment, but also assess the overall manufacturing environment. The smallest change to the part, part spectrum or material, type of contamination, or modifications to upstream or downstream processes is enough to seriously impair cleaning results. Thin-film residues According to the cleaning experts, a poor cleaning result or one that does not meet new higher requirements is a “classic” reason for carrying out a process analysis. The first step is to identify the exact problem – are thin-film cleanliness specifications not being fulfilled or are there stains on the parts? If staining is the problem, one of the questions to be asked is whether the quantity and composition of the contaminants (processing media and other substances) have changed or whether the constituents and concentration of the cleaning medium are still appropriate. Other factors, such as rinsing water quality, bath treatment, process technology and process sequence, as well as the drying step, are also closely examined. These are further influencing variables that play a role if thin-film cleanliness results are unsatisfactory. Particulate cleanliness If the cleanliness analysis after the cleaning cycle shows that too many, or too large, particles are still adhering to the parts, this may also be due to the cleaning program and process sequence used. Possible causes include residual particles in the working chamber or on the part carriers, an unsuitable filtration system or a clogged filter. Sometimes, it is the wrong choice of cleaning containers, such as crates made of

Cleaning processes often offer considerable potential for improvement when it comes to making parts cleaning operations more reliable, economical and sustainable. The first step is to carry out a systematic process analysis that also takes a close look at upstream and downstream production steps. To ensure the quality of subsequent process steps, avoid rejects and guarantee the functionality of the end product, consistent parts cleanliness is an essential quality criterion. Ever stricter or even modified cleanliness specifications must be met. In addition, demands on the speed, cost-effectiveness and sustainability of the cleaning process are constantly rising. However, how well, fast and efficiently the cleaning work is carried out depends not only on the equipment, the process technology and the medium used, but also on factors relating to the cleaning process itself. Process analysis So what do you do if parts suddenly come out of the system stained, if specifications for particulate or thin-film cleanliness are no longer met, the cleaned parts arrive at the customer’s corroded, or cleaning is too slow/too cost-intensive? In the case of these and other problems, a systematic process analysis such as that carried out by the Ecoclean Academy at Ecoclean GmbH can pinpoint the root cause of the error.

Thanks to systematic process analysis, which also includes the analysis of upstream and downstream production steps, sources of error and potential for improvement can be quickly identified

Regular inspection and maintenance of machine components such as filters are essential factors when it comes to meeting particulate cleanliness requirements in a consistent and economical manner

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TUBE PRODUCTS INTERNATIONAL November 2022

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